ARCHIVES OF CIVIL AND MECHANICAL ENGINEERING

Vol. VIII

2008

No. 4

Structure and hardness changes in welded joints

of Hardox steels
S. FRYDMAN, . KONAT, G. PKALSKI
Wrocaw University of Technology, Wybrzee Wyspiaskiego 27, 50-370 Wrocaw
In the article, the structure and change in hardness of the welded Hardox 400 and Hardox 500 steels
have been presented. It has been shown that structures of lower wear resistance are being created as a result of welding those materials in the as delivered state (i.e. with the tempered martensite structure)
within the heat-affected zones. They are as much as up to 90 mm wide, and that causes their non-uniform
and fast wear in the anticipated applications. Based on microscopic tests and hardness measurements
a method of thermal joints treatment has been proposed, consisting in their hardening and low-temperature tempering (self-tempering) at the heat-affected zones. It leads to reproduction of that area structure,
similar to the native material structure. In the laboratory conditions, a heat treatment differing from the
usual practice (stress-relief annealing or normalizing) has not led to welding incompatibilities (cracks).
Keywords: wear-resistant alloys, martensitic steels, welded joints, hardness changes, structures

1. Introduction
Based at test results concerning Hardox 400 and Hardox 500 steels collected
among others in [1], a proposal has been formulated of using those materials in the
surface mining machinery construction. The own test results [24] confirm good
weldability of the materials and very high strength properties of the joints obtained. As
a result of heat processes during welding, damage is being introduced into the as delivered structures in the heat-affected zones (tempered martensite). It introduces significant change in such area hardness, as well as local drop in wear resistance. Similar
phenomena are being observed in structural components cut out of metal sheets using
welding methods.
Significance of such phenomena is high when intending to use Hardox steel plates
for brown coal excavator parts, which are exposed to wear in the dynamic load conditions (chutes, hoppers, dumpers and scoop structure elements). The significance is
even higher, because they are usually being fixed to the main structure by welding.
Unfavourable structure and joint hardness appearing in low-carbon and low-alloyed
steels may be reversed by heat treatment of such joints (Figure 1). In case of toughened steel, martensitic steel, as well as hyperquenched and aged aluminum alloys, the
issues look different from the usual practice.
In the works [7, 8] they have been presented in relation to toughened steels in the
following statements:

16

S. FRYDMAN, et al.

in the heat-affected zone a problem of soft layer appears, which determines the
strength of the whole structure,
in the heat-affected zone of steel joints, hardened and tempered before welding,
changes appear which lead to creation of tempering zones of lowered hardness and
tensile strength.

Fig. 1. Hardness distribution in welded joints of the L35GSM cast steel with 18G2A steel:
as delivered, after stress relief annealing, after normalizing, W joint area,
HAZ heat-affected zone [5, 6]

Authors of the works [7, 8] and [911] state, however, that due to the proper
chemical composition of materials and proper selection of welding conditions and parameters, it is possible to obtain structures of similar material properties to the base
one in the heat-affected zone, without additional efforts. In case of welding with limited line energy the soft layer is very narrow and the joint exhibits no clear reduction
of mechanical properties. This is interpreted as reinforcing activity of neighbour
structural areas, as a result of three-axial stress creation in that zone.
Table 1. Chemical composition of Hardox 400, Hardox 500, HTK 700H and HTK 900H steels
C
Si
Mn
P
S
Cr
Ni
Mo
Material
Maximum values [%]
Hardox 400
0.320
0.700
1.600
0.025
0.010
0.300
0.250
0.250
Hardox 500
0.300
0.700
1.600
0.025
0.010
1.000
0.250
0.250
HTK 700H
0.180
0.450
1.400
0.025
0.010
0.500
0.300
0.030
HTK 900H
0.180
0.450
1.500
0.025
0.010
1.000
0.300
0.040
AR 400
0.240
0.700
1.700
0.025
0.010
1.000
0.700
0.500
Table 2. Structural properties of investigated steels
Material
Structure
Hardox 400
martensitic
Hardox 500
martensitic
HTK 700H
martensitic bainitic
HTK 900H
martensitic
AR 400
martensitic

B
0.004
0.004
0.002
0.003
0.004

Structure and hardness changes in welded joints

17

Hardox Steels, as well as HTK steels (Table 1 and 2) are well weldable materials
with low, or depending on conditions, crack sensitivity (susceptibility) (Figure 2). In
the as delivered state they have the structure of tempered martensite. According to the
producer data for those materials the hardness changes are as presented in Figure 3. As
it comes out of the graph, hardness reduction in the heat-affected zone could go as
high as 65% in relation to materials in the as delivered state. The extension of such
area of hardness reduction is not being determined by the steel producer. However, the
problem itself is being recognized in the form of recommendation for the zones to be
padded for hardening.

Fig. 2. Crack sensitivity of welded joints in Hardox 400 and Hardox 500, as well as HTK 700H and HTK
900H steels, for sheets of 8 mm thickness as a function of carbon contents and carbon equivalent:
P according to a producer data, W according to own chemical analysis [3, 12]

Fig. 3. Hardness change diagram in the welded joint of Hardox 400 steel [13]

However, the method does not solve the problem, as the hardening process of padding must cause new zones of unfavourable structural changes shifted toward edges of
padding weld. The following aims of the current studies emerge in the context of the
presented information:
identification of microscopic structure in welded joints of Hardox 400 and
Hardox 500 steels in the as delivered state and determination of structure and hardness
change extension caused by welding,
introduction of such structural transformations in joints by heat treatment as to
eliminate the changes to the maximum degree.

18

S. FRYDMAN, et al.

2. Study results
2.1. Welding conditions
Joints in Hardox steels have been performed using technology of submerged arc
welding (SAW), considering welding materials and parameters recommended by producer. As welding material the Multimet IMT9 3 mm (carbon contents 0.09 %) filler
wire and Lincoln Electric FX 780-25 flux have been used. The samples were made of
Hardox steel sheets of 500300 dimensions (8 mm thickness) joined with doublesided weld with the following parameters providing for correct material penetration:
minimum current for the first joint layer I1 = 300 A,
minimum current for the second joint layer I2 = 500 A,
electric arc voltage for both joint layers U = 30 V,
constant welding speed v = 0.35 m/min,
maximum linear energy: 2.57 kJ/mm.
Table 3 presents real chemical compositions of the welded steels. Their comparison
with producer data indicates for lower contents of alloy additions. This justifies for
more favourable location of points determining crack sensitivity of welded steels
(Figure 2).
Table 3. Real chemical compositions of the welded Hardox steels and filler wire
Material
C
Si
Mn
P
S
Cr
Ni
Hardox 400
0.120
1.050
0.34
0.006
0.001
0.240
0.040
Hardox 500
0.260
0.750
0.200
0.005
0.005
0.700
0.05
IMT9 Wire
0.090
0.140
1.000

Mo
0.017

B
0.002
0.001

Table 4. Heat treatment pattern and parameters for Hardox 400 and Hardox 500 steels
Sample marking
Pos.
Heat treatment pattern
Heat treatment parameters
Hardox 400
Hardox 500
As delivered state
1
I1
II 1

Hardening
2
I4
II 4
930C/20min/cooling in H2O
Hard./H2O/Temp.
3
I6
II 6
Temp. 200C/2h/air cooling
Hard./H2O/Temp.
4
I7
II 7
Temp. 300C/2h/air cooling

Table 4 presents methods and parameters of heat treatments applied to the joints
tested. They were performed in the as delivered state ( pos. 1), hardened after welding
( pos. 2) or after hardening and tempering ( pos. 2 and 3). Tempering temperature limitation to 300 C results from hardness and structure tests performed for the Hardox 400 and Hardox 500 steels within the tempering temperature range from 200 C to
700 C. Up to the tempering temperature of 300 C the steels preserve average hardness: 363 HV10 Hardox 400 and 428 HV10 Hardox 500. From the tempering temperature of 400 C their hardness drops fast, which excludes them from use in the
wear conditions.

Structure and hardness changes in welded joints

19

2.2. Joint structure and hardness changes in the as delivered state

Figure 4 presents exemplary structure of Hardox 500 steel as delivered. Joint
welding has introduced apparent changes and diversification in structure (Figure 5).
Graphs of hardness measurement (Figure 6 and 7) prove the extension of lowered
hardness zones. In case of Hardox 400 steel the zone is 70 mm wide, and for Hardox
500 it goes up to as much as 90 mm.

Fig. 4. Microstructure of Hardox 500 steel as delivered. Tempered martensite

without clear grain orders of the previous austenite. Mi1Fe etched, LM [2]

Fig. 5. Structure of welded joint of Hardox 500 steel in the fusion zone: W weld material,
HAZ heat-affecting zone. Arrows (1) indicate weak outline of the fusion area.
In the heat affecting zone a structure of post-martensitic orientation with areas of bainite (2)
and troostite (3) is clearly visible. Widmanstttens structures typical for significant over-cooling have
been observed locally. Mi1Fe etched, LM [2]

Also, the content of carbon in the joint material is clearly higher than it could result
from Table 3. It demonstrates itself with high quantity of fine-dispersive pearlite in the
joint material (Figure 5, zone W). A lack of welding incompatibilities is also a result
of macro- and microscopic observations of the tested joints.

20

S. FRYDMAN, et al.

Welded joint strength test results in the as delivered state have shown an average
joint strength of Hardox 400 steel equal to 615 MPa, and for Hardox 500 the strength
was 634 MPa. These are very high values and they constitute about 60% of the yield
point for Hardox 400 and about 50% for Hardox 500 steel.

Fig. 6. Hardness changes in welded joint of Hardox 400 steel in the as delivered state:
h 35 mm, weld hardness 210 HV10

Fig. 7. Hardness changes in welded joint of Hardox 500 steel in the as delivered state:
h 45 mm, weld hardness 230 HV10

2.3. Structures and hardness changes in joints after heat treatment

Overview of hardness changes and joint structures after heat treatment is presented
in Figures 816. Macro- and microscopic studies have not shown that joint failures in
the form of cracks appeared as a result of the heat treatment. All joint zones (marked
in Figure 5) have transformed structurally by changing towards the native material
structure in the as delivered state. Data concerning extension of the lowered hardness
zones have been collected in Table 5. Minimum values of hardness measurements in
the as delivered state have been assumed as border of that zone.

Structure and hardness changes in welded joints

21

Fig. 8. Hardness changes in welded joint of Hardox 400 steel after hardening. Maximum hardness in the
HAZ 410 HV10. Minimum hardness of the weld material 340 HV10

Fig. 9. Hardness changes in welded joint of Hardox 500 steel after hardening. Maximum hardness in the
HAZ 503 HV10. Minimum hardness of the weld material 430 HV10

Fig. 10. Structure of welded joint of Hardox 500 steel after hardening from the area marked with frame at
Figure 9. Martensitic structure of maximum hardness 503 HV10. Mi1Fe etched, LM

22

S. FRYDMAN, et al.

Fig. 11. Hardness changes in welded joint of Hardox 400 steel after hardening and tempering at 200 C
temperature. Maximum hardness in the HAZ 416 HV10

Fig. 12. Hardness changes in welded joint of Hardox 500 steel after hardening and tempering at 200 C
temperature. Maximum hardness in the HAZ 523 HV10

Fig. 13. Hardness changes in welded joint of Hardox 400 steel after hardening and tempering at 300 C
temperature. Maximum hardness in the HAZ 393 HV10

Structure and hardness changes in welded joints

23

Fig. 14. Hardness changes in welded joint of Hardox 500 steel after hardening
and tempering at 300 C temperature. Maximum hardness in the HAZ 417 HV10

Fig. 15. Material microstructure in welded joint of

Hardox 400 steel after hardening and tempering at
300 C temperature. Sorbitic type structure. Mi1Fe
etched, LM

Fig. 16. Microstructure of heat-affecting zone in

welded joint of Hardox 400 steel after hardening
and tempering at 300 C temperature.
Microstructure from area marked with frame
at Figure 13. Mi1Fe etched, LM

3. Summary
Measurement results in hardness change have been collected in Table 5. The following observations result from the data:
a) Width of the lower hardness zone in HAZ in relation to that zone width in the as
delivered state has been significantly limited as the result of all patterns of heat processing. Besides the case of hardening and tempering of the Hardox 500 steel at the
300 C temperature, the areas of lowered hardness have been narrowed by 3 to 6 times.
b) As a result of heat treatment the hardness of weld material has increased significantly. In extreme cases they changed by 70% for Hardox 400, and by 90% for
Hardox 500 steel. This indicates that also those areas should present higher wear
resistance in relation to the as delivered state.

S. FRYDMAN, et al.

24

c) In case of welding the Hardox 500 steel hardened and tempered at 300 C
temperature the width of lower hardness zone is similar to that as delivered. Essential
difference, however, constitutes a flattening of hardness change between native material and HAZ and weld material hardness. After heat treatment the HV10 290. That
indicates also for probable increase in wear resistance in the welded joint structure
change zone.
Table 5. Comparison of hardness measurement results
Pos.
1
2
3
4

h
HVW
HVMAX
[mm]
HV10
HV10
Hardox 400
35
210
375
As delivered
Hardox 500
45
230
440
Hardox 400
10
340
410
Hardened
Hardox 500
8
430
503
Hardened and tempered at
Hardox 400
8
330
416
200 C
Hardox 500
10
440
523
Hardened and tempered at
Hardox 400
12
363
393
300 C
Hardox 500
60
385
500
h width of lowered hardness zone, HVW weld material hardness,
HVMAX maximum hardness in HAZ, HVFZ maximum hardness in fusion zone
Welded joint state

Material

HVFZ
HV10
250
280
395
503
410
523
393
417

Microscopic tests have confirmed changes in structure of particular zones of

welded joints in relation to their structures at the as delivered state. The material
shows structural transformations consisting in:
a) Change in weld material structure from quasieutectoid with ferrite halo at grain
borders (Figure 5, area W) into a structure of low-carbon tempered martensite (Figure 15).
b) Obtaining the structure of tempered martensite in the whole heat-affected zone
(Figure 16). The structure is very similar to that of Hardox 500 steel in the as delivered state (Figure 4). Moreover, as a result of heat treatment the structure variation in
the fusion zone has been eliminated.
In the welded Hardox 400 steel the structural changes in various conditions of heat
treatment show departures from joint structures of Hardox 500 steel. They consist in:
a) Sorbitic, and not martensitic structure of weld material.
b) Narrow zone of fine ferrite grains (from the Hardox 400 steel side) in the fusion
zone.
c) Martensite structure with more advanced tempering process at the heat-affected
zone than in case of Hardox 500 steel (Figure 16).
From the data contained in Table 3, it results that difference in carbon density
between Hardox 400 steel and filler wire amounts to 0.03%, and between Hardox 500
steel and the wire to 0.17%. During welding, the carbon diffusion fluxes from Hardox
steel to the created weld are being initiated. That way, the weld material is being
enriched in that hardness improving element. In case of welding sheets of Hardox 500
steel this leads to martensitic type structures also in the weld material. Lowering the

Structure and hardness changes in welded joints

25

carbon contents in the fusion zone (from the Hardox 500 steel side) is not, however,
that intensive as not to allow reproduction during the heat treatment of the structure
similar to the native material as delivered.In Hardox 400 steel the saturation of weld
material with carbon could be lower as a result of its smaller contents in that steel.
Thus, hardenability of the weld material is insufficient for obtaining the martensitic
structure. A thesis could also be formulated concerning presence of a narrow strip of
equilibrium ferrite (from the Hardox 400 side) in the fusion zone. From that zone,
plenty of carbon passed to the weld material and, as a result, its hardenability was
lowered. The effect of that phenomenon is lack of low-carbon martensite in that zone.
The above assumptions could be confirmed by the results of spectral analysis of
chemical composition of the weld materials. They have shown:
average carbon contents higher by several hundredths of percent from 0.09,
higher carbon contents in joint connecting sheets of Hardox 500 steel than that of
Hardox 400.
The laboratory results indicate that in case of steel with martensitic structure a correction of joint hardness and structure is possible by means of hardening and tempering. This concerns the Hardox 400, Hardox 500 steels and, undoubtedly, the HTK
900H steel. That last one in the as delivered state has structure and hardness similar to
Hardox 400. Proposals of applying such heat treatment to welded joint have to arouse
some controversies and causes some technological problems. Usually (see Figure 1),
the relief or normalizing annealing processes are being applied to welded joints. It has
been proposed that during applying the last layer of weld a water jet followed an electrode causing hardening of the heat-affected zone (similar solution to the surface hardening). The cooling process would terminate at such point as to allow for self-tempering by heat cumulated in the material. Trials of welding and heat treatment of excavator scoop knives will be conducted in the second half of 2008. The proposal verification would follow during the operating experiment. Before such tests, metallographic studies of welded joints made at structure components of shapes and sizes
corresponding to the scoop knives will be conducted.
Hardox steels, and their Polish equivalents HTK steels, may find far wider application then before in the construction of basic machines for brown coal mining. It
simply comes out from their very high mechanical properties and uniform structure at
the sheet thickness (even exceeding 100 mm). The second of the features is very special one because, as opposed to the non-homogeneous padded layers, it allows for precise prediction of durability (the higher one from padding weld) of various type lining
plates. As shown in the paper [1], using the Hardox steel in real conditions consists in
uniform wear, without cracks and local thickness change. That is why they could be
used until complete wear. The only areas of intensive wear of such steel lining are
joints (stack welding) with the main structure. Should the failure be eliminated in
scoop lining and knives, a new, economically justified application area of those materials emerge [1].

26

S. FRYDMAN, et al.

Justification and inspiration for works at improving the structure and properties of
welded joints in Hardox and HTK steels may also be found among the modern materials for power industry. Martensitic steels, type 912% Cr (containing boron), are also
in consideration. Since developing the first of them (TAF steel from Japan, middle of
seventies in the 20th century), attempts of applying it to superheater pipes were restrained by its low elastic properties and inadequate weldability. It happened so even
despite its excellent resistance to creep. It required subsequent years to develop P91
and P92 steels and apply them to steam superheater header (e.g. at the Opole Power
Plant BOT). As an effect, the weight of piping dropped by some 30% and significant
investments and start-up savings were achieved [14]. It is not unlikely that similar way
the technology of welded joint heat processing for Hardox and HTK steels should pass
for the anticipated applications.
References
[1] Cegiel L., Konat ., Pawowski T., Pkalski G.: Hardox Steels New generations of construction materials for surface mining machinery, Brown Coal, Bogatynia, No. 3, 56,
pp. 2429.
[2] Konat ., Pkalski G., Oskwarek M.: Macro and microstructural properties of welded
joints of Hardox 400 and Hardox 500 steels, XIX Scientific Conference Development
Problems of Working Machines, Technical Magazine, Zakopane, January 2006.
[3] Oskwarek M.: Structural features and susceptibility to cracking of welded joints of
Hardox 400 and Hardox 500 steels, Conference Proceedings, IV Scientific Conference of
Students, Wroclaw University of Technology Publishing House, Wrocaw 2006.
[4] Bugacki H., Smajdor M.: Mechanical properties of abrasion resistant Hardox 400,
Advances in Material Science, Vol. 4, No. 2, 2003.
[5] Haimann R., Krajczyk A., Pkalska L., Pkalski G.: Analysis of strength changes and
development of technology for optimal annealing of welded parts (caterpillar girders,
caterpillar plates, a.s.o.), IMMT Report, series SPR 6, Wroclaw University of Technology, 1986.
[6] Haimann R., Krajczyk A., Pkalska L., Pkalski G.: Influence of relief annealing on the
structure and properties of cast steel joints with 18G2A and 12G2ANb steels, Welding
Technology Overview, 1990.
[7] Tasak E.: Metallurgy and structural metallurgy of welded joints, Script AGH Krakw,
1985.
[8] Engineer Handbook Welding Technology, T1, WNT, Warszawa 2003.
[9] Brooks J.A., Garrison Jr. W.M.: Weld Microstructure Development and Properties of Precipitation-Strengthened Martensitic Stainless Steels, Welding Journal, Aug. 1999.
[10] Li D., Lu B., Zheng X.: Fatigue Crack Initiation and Propagation in Butt Joint Welds of
an Ultrahigh-Strength Steel, Welding Journal, February 1993.
[11] Akselsen O.M., Rorvik G., Onsoien M.I., Grong O.: Assessment and Predictions of HAZ
Tensile Properties of High-Strength Steels, Welding Journal, September 1989.

Structure and hardness changes in welded joints

27

[12] tkowska B.: Material studies of HTK 700H, HTK 900H and AR400 steels and
potential of their application in surface mining machinery construction, Master Diplomma Thesis, Work Tutor G. Pkalski, PhD, 2007.
[13] Welding. Hardox, Weldox, Information Materials of the SSAB-Oxelsund Steel Mill.
[14] Hernas A.: Creep-resistance of steels and alloys, Silesian University of Technology
Publishing House, Gliwice, 2000.
Zagadnienia zmian struktur i twardoci pocze spawanych stali Hardox i HTK
W artykule przedstawiono budow strukturaln i zmiany twardoci pocze spawanych
stali Hardox 400 i Hardox 500. Wykazano, e w wyniku spawania tych materiaw w stanie
dostarczenia (o strukturze martenzytu odpuszczonego) w strefach wpywu ciepa powstaj
struktury obniajce odporno na zuywanie cierne. Maj one szeroko do 90 mm, co w przewidywanych zastosowaniach powoduje ich nierwnomierne i szybkie zuywanie. Na podstawie bada mikroskopowych i pomiarw twardoci, zaproponowano obrbk ciepln pocze polegajc na hartowaniu i niskim odpuszczaniu (samoodpuszczaniu) stref wpywu ciepa. Prowadzi to do odtworzenia struktur tego obszaru zblionych do struktury materiau rodzimego. Rnica si od zazwyczaj stosowanych (wyarzanie odprajce lub normalizujce)
obrbka cieplna nie wywoaa w warunkach laboratoryjnych powstawania w poczeniach niezgodnoci spawalniczych (pkni).